Textile webs



Dec. 29, 1959 E. BoBKowxcz 2,919,217

TEXTLE WEBS Filed June 5, 195s TEXTHJE WEBS Bobkowicz, Montreal, Quebec,Canada Application June s, 1953, serial No. 359,784 s Claims. (C1.154-46) t This invention relates to fabric Webs made from yarns,filaments or other strands of textile material.

More particularly, it relates to such fabric made from yarns of brousmaterial assembled in the form of Warp and weft layers bonded togetherby a heat-activated bonding agent.

The disadvantages of the normal processes of producing textile fabric byweaving are well known. Weaving is a method of fabric construction inwhich at least two sets of yarns are interlaced at right angles.Interlacing of yarn is thus the basic foundation to form a weave orfabric and gives the fabric its strength. So far there have been noreally practical solutions to avoid the complexities of normal weavingand yet to provide fabric -which has the desirable characteristics ofwoven textile fabrics.

Because of the disadvantages of weaving, there have been attempts tomake unwoven fabric from fibers. These non-woven fabrics are verysuitable for particular uses but are not applicable in many of thefields in which conventional woven fabrics are employed, particularlybecause they lack strength or are not suiiiciently porous.

The applz'cants development The applicant now provides a fabric webwhich has many of t-he desirable characteristics, including appearanceand hand, of material Woven from yarns in the normal way, but which ismade avoiding the bottleneck of conventional weaving, i.e. interlacing.

The method of theinvention involves a series of steps which can beperformed without the complicated and costly equipment necessary in thenormal weaving operation.

And, the apparatus employed is simpler than the normal weaving apparatusand can be operated at a higher capacity and with less attention.

A textile weave according to the invention comprises at least one warplayer down or up, made up of a plurality yof undividual yarns, at leastone weft layer up or down, made up of a plurality of individual yarns.The individual yarns of the warp and weft layers are separated byinterstices. The warp and wefty layers are separate but in directcontact, i.e., are juxtaposed without lbeing interlaced, the respectivethreads with an imparted or added thermoplastic or thermosetting agentbeing welded together at contact points by the action of heat, createdby radiant or Shortwave heating and by application of pressure so as tocause the weft and warp yarns to be crimped by crossing warp and weftyarns, by cooling action while the bonding agents are still plastic andunder pressure, to cause coagulation to stabilize the form of awoven-like web without interlacing of the yarns. So, the web has muchthe appearance of a woven web. The web also has other characteristics,for example, hand, strength and breeze (permeability to air) of a wovenweb made from yarns.

The weft `yarns are preferably longer than the normal width of the warpand are inturned over the edge of the web and under heat and pressurewelded in this position by the-bonding agent to form a selvedge.

' arent Patented Dec. 29, 1959 complished by a method forming a part ofthis invention.

The method according to the invention comprises the following steps. Thewarp yarns are fed from a suitable source of supply to form a first Warpwhich is continuously conveyed through a constructional path.

While the warp is conveyed through this path a iirst lweft layer is laidas follows.

Weft yarns are conveyed from a suitable source of supply to form acontinuous weft layer. Successive sections of this weft layer arebrought into contiguity with the warp layer at a first yweft applyingstation. The section of the weft layer is then severed from thesucceeding sections and conveyed through the constructional pathcontiguously to the warp layer. This operation is repeated at the firststation so that one weft yarn section after the other is brought intocontiguity with the warp side by side with the previous weft yarnsection and the continuous weft so formed is conveyed through theconstructional path in contiguity with the warp.

Warp threads are then brought from a second source of supply to form asecond warp layer. This second warp layer is guided at a second stationinto contiguity with the warp and weft yarns previously laid. The secondwarp layer is conveyed from this second station in contiguity with thecontinuous weft yarns above referred to and is carried in suchrelationship continuously through the constructional path.

Then, at a third station a second continuous weft layer is formed in thesame manner as the first weft layer and this weft layer is carriedthrough the constructional path in contiguity with the previously laidlayers. Then, at a fourth station a third warp layer is laid and carriedthrough the constructional path in contiguity with the previously laidlayers.

At a subsequent station a thermoplastic or thermosetting bonding agentis applied to the composite fabric, if necessary. Then, at a subsequentstation, heat is applied to the web to activate the bonding agent.

Then the web with the bonding agent softened is subjected to pressure topress the respective layers -together and cause the yarns to assume anundulating ycondition by virtue of indentation by ladjacent yarns. Then,the bonding agent is allowed to cool to vstabilize the resulting webwith the respective yarns welded together at their contact points.

The weft threads extend laterally beyond the warp and are cut off or areinturned after heating'and pressed to form a selvedge on the web.

In fact now that the invention has been generally summarized, preferredembodiments of it will be described in more detail by reference to theaccompanying drawings, in which:

Figure 1 is a perspective View showing diagrammatically the formation ofa textile weave according to the present invention.

Figure 2 is a cross-section along the .line 2-2 of Figure 1. v

Figure 3 is a cross-section along the line 3-3 of Figure l.

Figure 4 is a cross-section .along the line 4-4 of Figure 1.

Figure 5 is a cross-section along the line 5--5 of Figure l.

Figure 6 is a cross-section along the line 6-6 of Figure 1.

Figure 7 is a top plan view of one form of weave yaccording to theinvention with the upper layers of `yarn partlyremoved to show theconstruction underneath.

Figure 8 is a view similar to that of Figure 7 showing another type ofweave according to the invention.

Web

Referring in more detail to the drawings, Figure 1 is a diagrammaticperspective view illustrating one form of textile web being madeaccording to the invention.

This web is made up of a lower warp layer W, a weft layer S immediatelyon top of the warp layer W, a warp layer T on top of the weft layer S, aweft layer P on top of the warp layer T and a top warp layer N on top ofthe weft layer P. As shown, the weft yarns extend outwards from thewarps at each side of the fabric. As indicated on the left hand side ofthe figure these protruding ends are inturned and lapped over the edgeof the fabric to form a selvedge.

As perhaps better illustrated in Figures 2 and following, the warp andweft yarns are not interlaced as in normal textile fabric. They arejuxtaposed and pressed into interstices between adjacent yarns. 'Theconnection between the respective warp and weft yarns is by aheatactivated bonding agent, for example, a thermoplastic orthermosetting material which has been applied either to the yarnsbeforehand or to the laminae during the formation of the compositefabric. The respective yarns of each warp and weft layer are spacedapart laterally enough to permit breathing of the fabric, thus avoidingthe disadvantage of non-woven fabrics made from bers. The web may bemade up of three warps and two wefts as, for example, shown in Figure 7.Or, it may be a simpler fabric as shown in Figure 8 in which there arewarps and a single weft. Many variations are possible in the number oflaminae.

While the web is not woven it is pressed during formation so that theweft and warp threads are pressed against each other causing them toundulate and to ll interstices between adjacent juxtaposed yarns.

The welded contact surface between the yarns is not only considerablyincreased, but the yarns of the middle layers are surrounded by theadjoining yarns forming simulated interlacing. The large welded surfaceand the interlacing-like composition and welded salvage gives aconsiderable strength to the weave and enables the applicationsimultaneously of several times more weft yarns per second than thefastest automatic loom.

Figure 4 illustrates the relationship between three warps and two weftsbefore pressure has been exerted to force the warp threads inwards tocause undulation of the weft and warp yarns.

The yarns used in the process may be prepared in accordance with theapplicants co-pending application S.N. 284,284, led April 25, 1952. Inthis case they will contain bonding agent ready for softening andfurther bonding agent may or may not be applied at the applicationstation.`

Fibers employed Fibers which may be employed in the yarn or twine usedfor making webs according to the invention include any kind of naturalor man-made staple bers or continuous filaments. As suitable examples ofnatural bers may be mentioned cotton, jute, kenaf, ramie, sisal, hemp,ax, wool. Two or more types of bers may be combined.

Bonding agents The bonding agents which may be employed for weldingtogether the yarns include heat activated materials, i.e. thermoplasticor thermosetting plastic materials, as contrasted with mere adhesives,for example, glue. The bonding action is performed by the reaction ofthe bonding agents under heat and subsequent coagulation by coolingwhich, in effect, welds the fibers together. v The selection of thesuitable bonding agent for the particular purpose will be within theability of one skilled in the art.

Among suitable bonding agents may be mentioned thermoplastic orthermosetting materials, for example, cellulose esters and celluloseethers or mixtures thereof, vinyl resins, polystrene, acrylics,polyethylene, nylon and related plastic materials, polyoletns andrelated plastic materials, thermosetting resins, for example,phenolformaldehyde and ureaformaldehyde resins.

The amount of bonding agent employed may vary widely and this again iswithin the scope of one skilled in the art. In certain cases the amountof bonding agent may vary from about 15% by weight on the fiber up tosay about 50%. The bonding agent may contain up to about 30%plasticizer. These figures are given merely by way of example since theamounts may vary widely.

The yarns may vary widely in denier as will be clear to one skilled inthe art.

I claim:

1. A textile web, comprising at least one warp layer made up of aplurality of substantially parallel closely spaced individual yarns andat least one weft layer made up of a plurality of individual yarns, allsaid yarns being ymade up of textile fibers held together with aheat-activated bonding agent the Warp and weft layers being separate butthe yarns thereof being in direct contact at points throughout theirarea, the respective yarns being welded together at contact points bysaid bonding agent, the warp and weft layers being pressed together sothat the respective yarns are crimped by crossing yarns to give the websubstantially the appearance, strength, permeability to air and hand ofa normal textile weave of substantially regular construction, the webbeing stabilized in this condition by the bonding agent distributedsubstantially throughout the web.

2. A web according to claim 1, in which the weft yarns extend outwardbeyond the warp yarns and are inturned to overlap the edge of the weband bonded by said bonding agent under heat and pressure in saidposition to form a selvedge.

3. A textile fabric, according to claim 1, in which there are aplurality of warp layers.

4. A fabric according to claim 1, in which there are a plurality of warplayers and a plurality of weft layers.

5. A textile web comprising at least three warp layers and a weft layerintervening the respective warp layers, each layer being made up of anumber of substantially parallel closely spaced individual yarns andimpregnated with a heat-activated bonding agent, the warp and weftlayers being separate but in direct contact at points throughout theirarea, the yarns o-f one warp layer being spaced and placed so as to bein staggered relation to those of the next warp layer, the yarns of theweft layer being spaced and placed so as to be in staggered relation tothose of the next weft layer, the yarns of respective layers beingwelded together in a pressed condition at said contact points by theheat activation and coagulation of the bonding agent, the warp and weftlayers being pressed together so that the respective yarns are crimpedby crossing yarns and being stabilized in this condition by the setbonding agent to give the web substantially the appearance, strength,air permeability and hand of a normal textile weave.

References Cited in the le of this patent UNITED STATES PATENTS 753,752Stewart Mar. 1, 1904 1,188,571 Subers June 27, 1916 1,314,519 HowardSept. 2, 1919 1,593,956 Sill July 27, 1926 1,890,869 St. Clair Dec. 13,1932 1,942,086 Cheatham Jan. 2, 1934 2,266,761 Jackson et al Dec. 23,1941 2,485,827 Hartzell Oct. 25, 1949 2,522,527 Manning Sept. 19, 19502,574,221 Modigliani NOV. '6, 1951 2,599,3594 Banks et al. .lime 3, 1952

1. A TEXTILE WEB,COMPRISING AT LEAST ONE WARP LAYER MADE UP, OF APLURALITY OF SUBSTANTIALLY PARALLEL CLOSELY SPACED INDIVIDUAL YARNS ANDAT LEAST ONE WEFT LAYER MADE FUP OF A PLURALITY OF INDIVIDUAL YARNS, ALLSAID YARNS BEING MADE UP OF TEXTILE FIBERS HELD TOGETHER WITH AHEAT-ACTIVATED BONDING AGENT THE WARP AND WEFT LAYERS BEING SEPARATE BUTTHE YARNS THEREOF BEING IN DIRECT CONTACT AT POINTS THROUGHOUT THEIRAREA, THE RESPECTIVE YARNS BEING WELDED TOGETHER AT CONTACT POINTS BYSAID BONDING AGENT, THE WARP AND WEFT LAYERS BEING PRESSED TOGETHER SOTHAT THE RESPECTIVE YARNS ARE CRIMPED BY CROSSING YARNS TO GIVE THE WEBSUBSTANTIALLY THE APPARANCE, STRENGTH, PERMEABILITY TO AIR AND HAND OF ANORMAL TEXTILE WEAVE OF SUBSTANTIALLY REGULAR CONSTRUCTION, THE WEBBEING STABILIZED IN THIS CONDITION BY THE BONDING AGENT DISTRIBUTEDSUBSTANTIALLY THROUGHOUT THE WEB.